Pressure Actuated Piston Type Casing Fill-up Valve and Methods of Use Thereof

ABSTRACT

The present disclosure describes a method and apparatus for filling casing and/or a casing string and provides for the flow back of such fluids in a wellbore during casing running operations. The tool comprises a piston valve which is automatically pressure actuated. Thus, the valve will open and close without manual and/or outside mechanical intervention. Further, the design and construction of the piston valve helps to substantially reduce erosive wear to the piston valve and its components.

TECHNICAL FIELD

The present disclosure relates generally to the drilling of subterranean wells and, more particularly to filling casing and casing string with drilling fluid and providing for the flow back of said fluids.

BACKGROUND OF THE INVENTION

The process of drilling subterranean wells to recover oil and gas from reservoirs, typically consists of boring a hole in the earth down to the petroleum accumulation and installing pipe from the reservoir to the surface. Casing is generally a protective pipe liner within the wellbore that may be cemented in place to insure a pressure-tight connection to the oil and gas reservoir. The casing is typically run in single or multiple joints at a time as it is lowered into the wellbore. On occasion, the casing becomes stuck and is unable to be lowered into the wellbore. When this occurs, load must be added to the casing string to force the casing into the wellbore, or drilling fluid must be circulated down the inside diameter of the casing and out of the casing into the annulus in order to free the casing from the wellbore. To accomplish this, it has traditionally been the case that special rigging be installed to add axial load to the casing string or to facilitate circulating the drilling fluid.

When running casing, drilling fluid is added to the casing section(s) as it is run into the wellbore. This procedure is necessary to prevent the casing from collapsing due to high pressures within the wellbore. The drilling fluid acts as a lubricant which facilitates lowering the casing within the wellbore. As joints of casing are added to the string, drilling fluid is displaced from the wellbore. Typically, hose assemblies, housings coupled to the uppermost portion of the casing, and/or tools suspended from the drill hook for filling the casing were utilized. Others employed sealing elements which would seat against the inside of the casing, followed by a mechanical setdown force which opened ports to allow for circulation. Seals between a mandrel and a movable sleeve were also needed to retain a sealed connection to allow circulation. Filling in these devices was accomplished by displacement of a valve member past a lateral port to expose the lateral port to allow the casing to fill. Frequently, excessive erosion occurred at the valve member used for filling the casing, undermining its reliability. Additionally, some designs required at least two separate valves, one for filling the casing and the other for circulating the fluid. Typically, the circulating ports had to be mechanically exposed using setdown weight or other manual intervention. In addition to erosion, additional valve components were required for operation.

Circulating of the fluid is some times necessary if resistance is experienced as the casing is lowered into the wellbore. In order to circulate the drilling fluid, the top of the casing must be sealed so that the casing may be pressurized with drilling fluid. Since the casing is under pressure the integrity of the seal is critical to safe operation, and to minimize the loss of the expensive drilling fluid. Once the casing reaches the bottom, circulating of the drilling fluid is again necessary to test the surface piping system, to condition the drilling fluid in the hole, and to flush out wall cake and cuttings from the hole. Circulating is continued until at least an amount of drilling fluid equal to the volume of the inside diameter of the casing has been displaced from the casing and wellbore. After the drilling fluid has been adequately circulated, the casing may be cemented in place.

BRIEF DESCRIPTION OF DRAWINGS

For a further understanding of the nature and objects of the instant disclosure, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements are given the same or analogous reference numbers.

FIG. 1 illustrates a pictorial view of a self actuating casing tool in accordance with the present disclosure;

FIG. 2 illustrates an exploded view of a pressure actuated piston type casing fill-up valve in accordance with the present disclosure; and

FIG. 3 illustrates a cross sectional view of a pressure actuated piston type casing fill-up valve in accordance with the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

The present disclosure provides a device that simplifies the construction of an apparatus utilized for filling and circulating fluid within casing and/or a wellbore. The disclosed device provides, among other things, an automatic piston type pressure actuated valve which allows fluid, such as drilling fluid, to pass through the valve and into the casing without intervention. As described hereinbelow, the piston allows for activation without manual assistance or other manipulation of the valve. Further as the fluid flow is discontinued, the valve closes due to the substantial lack of pressure and retains the fluid in the casing. It should be appreciated that the fluid may exit at the bottom of the casing string and move into the wellbore.

Referring now to FIG. 1, an embodiment of the self actuating casing tool 2 is illustrated. Preferably, the self actuating casing tool 2 comprises a hook 4 which may adapt to conventional type Kelly systems. It should be further understood that hook 4 is for a connection to a conventional rig drive. However, connections directly to top drives as well as a variety of other connections are envisioned and as such should not be viewed as a limitation thereof. Further, a connection 6 is preferably provided for connection to a hose to provide drilling fluid or mud for the filling of the casing joints and/or casing string. It should be understood that connection 6 is for example only and that a variety of connections, for fluid, may be utilized. Preferably, the casing tool 2 will have an additional length section 8 which allows for length adjustment and/or to provide travel limitation, when the tool is utilized in conjunction with a conventional push plate 10. It should be understood that push plate 10 may also serve to limit travel of the tool 2 and is preferably adjustable along the length of section 8.

Below push plate 10, there are preferably one or more subs 12. Sub or subs 12 are preferably used to adust the correct length of tool 2 to provide for the desired operational use of tool 2. The sub or subs 12 preferably comprise threaded ends for connection purposes. It should be understood that the connection, of the sub or subs 12 can be a variety of connection methods such as but not limited to left hand threads to deter disconnection, of the sub or subs 12, during tool operation and thus the specific configuration of the connection should not be viewed as a limitation herein. In at least one embodiment, the subs 12 are designed so as to allow multiple re-cuts on the connection threads. It should be appreciated that the connection threads of the sub or subs 12 can be worn or damaged after several uses due to environmental conditions and/or corrosion/erosion. It should be further appreciated that the multiple re-cuts allow for quick and/or easy repair of the subs 12.

Preferably, between the pressure actuated piston type casing fill-up valve 16 and the sub or subs 12 are one or more sealing elements 14. It should be understood that the exact configuration and/or location of the sealing members 14 may vary regarding the preferred/required distance in order to achieve the proper placement of the pressure actuated piston type casing fill-up valve 16 and the sealing elements 14. It should be further understood that elements 14 may be conventional sealing elements well known in the art and utilized to seal against the internal casing wall to allow fluid circulation.

In at least one embodiment and as described hereinbelow, the pressure actuated piston type casing fill-up valve 16 is manufactured of materials or coated with materials or incorporates specifically treated materials which help to eliminate and/or reduce wear in the pressure actuated piston type casing fill-up valve 16.

FIG. 2 illustrates an exploded view of a pressure actuated piston type casing fill-up valve 16. In one embodiment, pressure actuated piston type casing fill-up valve 16 preferably comprises a lower cylinder 30. Preferably lower cylinder 30 has at least one port 32 at the lower end. It should be understood that there may be several ports 32 and that the exact position of the ports 32 should not be viewed as a limitation herein. The purpose of the fluid port 32 is to allow the passage of the desired fluid, such as drilling mud, through the casing tool 2 and into the casing and/or casing string. Piston 28 is designed so as to fit into lower cylinder 30. The cylinder head 26 preferably fits into lower cylinder 30 on top of the piston 28. Preferably, cylinder head 26 is designed with a retaining lip 27. Preferably, retaining lip 27 will align with a mating retaining lip 23 in the interior top portion of lower cylinder 30. It should be appreciated that the configuration of the mating retaining lips 23, 27 can be varied. It should be further appreciated that the purpose of the mating retaining lips 23, 27 is to retain the cylinder head 26 in position. Thus, piston 28, when fluid pressure is applied to it, can move away from the cylinder head 26 allowing for the flow of fluid through the piston bore 33. Upper cylinder portion 18 connects to lower cylinder 30 thus enclosing the piston 28 and cylinder head 26. It should be appreciated that upon the connection of upper cylinder portion 18 and lower cylinder 30, the retention of cylinder head 26 is achieved, preferably due to the mating of retaining lips 23, 27. Preferably lower cylinder 30 has a connection 24 and the upper cylinder 18 has a connection end 22. Although it is preferable that the connections 22, 24 be a mating threaded connection, other methods of attachment are foreseeable and should not be viewed as a limitation herein. Further, upper cylinder portion 18 preferably has a conventional pipe thread connection 20 at its upper end. Preferably, the pressure actuated piston type casing fill-up valve 16 and various internal parts are protected against the erosive forces of the drilling fluid as well as other wellbore environmental conditions. In one example, not intended as limiting, the cylinder head 26 is made of a tungsten carbide material and the mating portion of the piston 28 is also of a tungsten carbide material. It has been found that a material with a higher cobalt content provides better erosive resistance. In other examples, also not intended to be limiting, certain pressure actuated piston type casing fill-up valve 16 parts may be gas nitrided for erosive resistance. It should be understood that there may be other methods of protecting the parts against erosion and should not be viewed as a limitation herein.

Referring now to FIG. 3 a cross sectional view of an embodiment of a pressure actuated piston type casing fill-up valve 16 is illustrated It can be seen here the functional relationship between the various components described herein above. It should be understood that one or more seals may be employed, as necessary, to prevent leakage. In this embodiment, one or more seals 34 are utilized to seal the connection 22, 24 of the upper cylinder 18 and the lower cylinder 30. Another seal 36 or set of seals are preferably utilized for sealing between the lower cylinder 30 and the piston 28.

Still referring to FIG. 3, there is illustrated a spring 29. Preferably spring 29 is designed so as to bias piston 28 in a substantially seal tight relationship with cylinder head 26 when there is no fluid flow through the pressure actuated piston type casing fill-up valve 16. Thus, the pressure actuated piston type casing fill-up valve 16 remains in a closed position until the force of the fluid, passing through pressure actuated piston type casing fill-up valve 16, is sufficient to overcome the bias of spring 29. It should be appreciated that methods, other than a spring, for biasing may be utilized and should not be viewed as a limitation herein.

In operation, the fluid, such as but not limited to drilling mud enters the pressure actuated piston type casing fill-up valve 16 through upper port 38. As the fluid contacts the cylinder head 26, piston 28 will be displaced, by the fluid pressure. Preferably, the displacement, of piston 28 occurs as the fluid passes around the substantially stationary cylinder head 26. The fluid can then move through the piston bore 33 and into the casing through the lower ports 32. When the fluid flow is shut off, the spring 29 will move the piston 28 back to its normal or unactuated position and any flow, through the pressure actuated piston type casing fill-up valve 16 is prevented. It should be appreciated that wellbore pressure, below the pressure actuated piston type casing fill-up valve 16, may aid in moving the piston in contact with the cylinder head 26 thus further preventing any reverse flow through the pressure actuated piston type casing fill-up valve 16.

While the present system and method has been disclosed according to the preferred embodiment, those of ordinary skill in the art will understand that other embodiments have also been enabled. Even though the foregoing discussion has focused on particular embodiments, it is understood that other configurations are contemplated. In particular, even though the expressions “in one embodiment” or “in another embodiment” are used herein, these phrases are meant to generally reference embodiment possibilities and are not intended to limit the system or methods disclosed herein to those particular embodiment configurations. These terms may reference the same or different embodiments, and are combinable into aggregate embodiments. The terms “a”, “an” and “the” may also mean “one or more”.

When a single embodiment is described herein, it will be readily apparent that more than one embodiment may be used in place of a single embodiment. Similarly, where more than one embodiment is described herein, it will be readily apparent that a single embodiment may be substituted for that one device. In light of the wide variety of casing filling activities, the detailed embodiments are intended to be illustrative only and should not be taken as limiting the scope of the instant disclosure. None of the description in this specification should be read as implying that any particular element, step or function is an essential element which must be included in the claim scope. Unless explicitly recited, other aspects of the instant disclosure as described in this specification do not limit the scope of the claims. Because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught, and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. Obviously, other modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments described above which are within the full intended scope of the invention as defined in the appended claims. 

1. A pressure actuated piston type fill-up and circulation valve for moving fluid into a tubular or tubular string and/or into a wellbore comprising: a valve body having an outer surface, an inner surface defining a bore therein, and a lower end, said lower end defining at least one aperture therein; a piston movably insertable in said bore; said piston having an outside surface and further defining a flow bore therethrough; and a blocking member, said blocking member configured to seal said piston flow bore, wherein said piston flow bore is sealed when said piston is substantially in contact with said blocking member.
 2. The pressure actuated piston type fill-up and circulation valve of claim 1, further comprising a spring, said spring biasing said piston in a direction away from said lower end and toward said blocking member.
 3. The pressure actuated piston type fill-up and circulation valve of claim 2, wherein said spring is mounted adjacent to said outside surface of said piston.
 4. The pressure actuated piston type fill-up and circulation valve of claim 1, wherein said blocking member comprises a material for erosion resistance.
 5. The pressure actuated piston type fill-up and circulation valve of claim 4, wherein said blocking member is constructed of tungsten carbide.
 6. The pressure actuated piston type fill-up and circulation valve of claim 1, wherein said lower end defines two apertures therein.
 7. The pressure actuated piston type fill-up and circulation valve of claim 1, further comprising an upper body configured to matingly connect to said valve body.
 8. The pressure actuated piston type fill-up and circulation valve of claim 7, wherein the connection of said upper body and said valve body substantially retains said blocking member.
 9. The pressure actuated piston type fill-up and circulation valve of claim 1, further comprising a seal mounted on said piston.
 10. A method for moving fluid into a tubular or tubular string and/or into a wellbore through a pressure actuated piston type fill-up and circulation valve comprising the steps of: providing a pressure actuated piston type fill-up valve having an inlet port, a piston therein, and at least one outlet port, mounted adjacent to said bottom end of the valve, wherein said piston defines a flow bore therethrough; mounting a blocking member between said inlet port and said piston; biasing said piston in a direction away from the bottom end of said body and toward said blocking member; blocking flow through said piston when said piston is biased against said blocking member and substantially in contact with said blocking member; moving fluid to apply pressure to a top surface of said piston; moving said piston away from said blocking member, in a direction towards said bottom end of said body, wherein moving comprises increasing pressure of fluid until said pressure overcomes said biasing of said piston; moving fluid into said tubular or tubular string and/or into said wellbore; and stopping fluid flow, wherein said stopping removes pressure on piston surface and allows piston to return to biased position.
 11. The method of claim 10, wherein said biasing is with a spring mounted adjacent to said piston.
 12. The method of claim 10, wherein the blocking member is configured so as to allow fluid contact with the top surface of the piston.
 13. The method of claim 10, further comprising the steps of: providing an upper body of the valve and a lower body of the valve; and retaining the blocking member between said upper body and said lower body.
 14. A fill-up and circulating tool for inserting into the upper end of a tubular or tubular string to move fluid into and to circulate fluid from inside the tubular or tubular string into a wellbore for use on drilling and/or workover rigs, the fill-up and circulating tool comprising: a body having a top end, a bottom end, an inlet, an outlet, an outer surface, and a central axial bore defining a flow path therethrough; said body further having a connection adjacent to said top end, said connection adapted to connecting to a rig and/or rig drive; said body further being configured to adapt to a push plate; at least one sealing element, said sealing element disposed about said body for sealing engagement with the tubular or tubular string, wherein said sealing engagement being against an internal diameter of said tubular or tubular string; and a pressure actuated piston type fill-up valve, having at least one outlet port, mounted adjacent to said bottom end of said body, wherein said pressure actuated piston type fill-up valve allows for said fluid to be moved into said tubular or tubular string and/or into said wellbore, and wherein fluid flow automatically moves a piston in a direction away from said body.
 15. The fill-up and circulating tool of claim 14, wherein said pressure actuated piston type fill-up valve further comprises: a valve body having an outer surface, an inner surface defining a bore therein, and a lower end, said lower end defining at least one aperture therein; a piston insertable in said bore; said piston further defining a flow bore therethrough; a spring, said spring biasing said piston in a direction away from said lower end; and a blocking element, said blocking element configured to seal said piston flow bore, wherein said seal is accomplished when said piston is in contact with said blocking element.
 16. A pressure actuated piston type casing fill-up and circulation valve comprising: a lower valve body having an outer surface, an inner surface defining a bore therein, and a lower end, said lower end defining at least one aperture therein; an upper valve body having an inlet port; a piston insertable in said bore; said piston having an outside surface and further defining a flow bore therethrough; a biasing member, said biasing member biasing said piston in a direction away from said lower end; and a blocking member, said blocking member configured to seal said piston flow bore, wherein said seal is accomplished when said piston is in contact with said sealing device, and wherein said blocking member is retained between the lower valve body and the upper valve body.
 17. The pressure actuated piston type casing fill-up and circulation valve of claim 16, wherein said biasing member is a spring, and wherein said spring is mounted adjacent to said outside surface of said piston.
 18. The pressure actuated piston type casing fill-up and circulation valve of claim 16, wherein said lower end defines two apertures therein.
 19. The pressure actuated piston type casing fill-up and circulation valve of claim 16, wherein the connection of said upper body and said valve body further comprise a sealing member between said upper body and said valve body.
 20. The pressure actuated piston type casing fill-up and circulation valve of claim 16, further comprising a seal mounted on said piston. 